C&I SOLAR PROJECT INSTALLATION AND MINI GRID COURSE OUTLINE

REVISION

MODULE 1: Introduction to C&I Solar Systems
 Overview of solar energy in commercial & industrial applications
 Differences between residential vs C&I systems
 Types of C&I systems:
 Key components of a solar system:
 Industry standards and regulations

MODULE 2: Energy Audit & Load Assessment in a C&I Project
 Understanding electrical loads in C&I project
 Load categorization:
 How to carry out a site energy audit in C&I project
 Load estimation and demand profiling
 Peak load vs average consumption
 Power factor and its importance

MODULE 3: System Sizing & Design
 Solar system sizing principles
 Panel sizing (based on energy demand)
 Inverter sizing (string, central, hybrid)
 Battery bank sizing (especially lithium battery design)
 Days of autonomy calculation
 Depth of Discharge (DoD) considerations
 Cable sizing and voltage drop calculations
 Designing for scalability and future expansion

MODULE 4: Solar Resource & Site Assessment
 Understanding solar irradiation
 Tilt angle and orientation optimization
 Shading analysis
 Roof vs ground-mounted systems
 Structural considerations for C&I installations
 Site survey tools and techniques

MODULE 5: System Components Deep Dive
 Solar Panels
 Efficiency and performance factors
 Inverters
 Grid-tied vs hybrid vs off-grid
 String vs central inverters
 Inverter communication systems
 Batteries (Lithium Focus)
 Types of lithium batteries (LiFePO4, etc.)
 The right lithium batteries for C&I project
 Battery Management System (BMS)
 Cell balancing and protection mechanisms
 Other Components
 Combiner boxes
 Protection devices (MCB, MCCB, SPD)
 Earthing systems

MODULE 6: Electrical Design & Protection
 AC and DC wiring design
 Earthing and grounding systems
 Lightning protection systems
 Circuit protection design
 Isolation and switching devices
 Safety standards and compliance

MODULE 7: Installation Process (Hands-On)
 Victron and Fronius setup as a case study
 Step-by-step installation guide:
 Mounting structure setup
 Panel installation
 DC cabling
 Inverter installation
 Battery installation (lithium focus)
 AC wiring and integration
 Cable management best practices
 Labeling and documentation
 Practical site work

MODULE 8: Battery Integration & BMS Configuration
 Lithium battery pack connection techniques
 BMS wiring and setup
 Communication protocols (CAN, RS485)
 Monitoring apps (e.g., Xiaoxiang, JBD)
 Parameter configuration:
 Voltage limits
 Current limits
 Temperature protection
 Safety precautions

MODULE 9: Commissioning & Testing
 Pre-commissioning checklist
 System testing procedures
 Performance verification
 Troubleshooting common issues
 System optimization
 Documentation and handover

MODULE 10: Monitoring & Maintenance
 System monitoring tools and platforms
 Preventive maintenance practices
 Fault detection and diagnostics
 Cleaning and inspection routines
 Performance tracking

MODULE 11: Troubleshooting & Fault Handling
 Identifying common faults:
 Low output issues
 Inverter faults
 Battery issues
 Step-by-step troubleshooting approach
 Use of diagnostic tools
 Repair and replacement strategies

MODULE 12: Health, Safety & Environmental (HSE)
 Electrical safety practices
 Working at height safety
 PPE usage
 Fire safety in solar installations
 Risk assessment and hazard control

MODULE 13: Financial Analysis & Project Management
 Cost estimation for C&I projects
 ROI (Return on Investment) analysis
 Payback period calculation
 Project budgeting
 Proposal writing and client presentation
 Procurement and logistics planning

MODULE 14: Business & Career Opportunities
 Starting a solar installation business
 Marketing solar solutions
 Client acquisition strategies
 Building partnerships
 Scaling a solar company

MODULE 15: Practical Project (Capstone)
 Real-life C&I system design
 Full installation simulation
 System commissioning
 Performance evaluation

MINI GRID
Module 16: Mini-Grid System Components
Solar Generation System
• PV modules
• Mounting structures
Energy Storage
• Battery technologies
o Lead-acid batteries
o Lithium-ion batteries
• Battery management systems (BMS)
Power Conversion
• Charge controllers
• Inverters
• Hybrid inverters
Distribution Network
• Poles
• Conductors
• Distribution transformers (where applicable)
• Protection devices
Metering
• Smart meters
• Prepaid meters
• Energy monitoring systems
Practical
• Component identification
• Installation demonstrations

Module 17: Site Assessment and Survey
• Resource assessment
• Solar path analysis
• Load assessment
• Community energy demand survey
• Topographical considerations
• Environmental impact assessment
Practical
• Conducting a site survey
• GPS mapping
• Shading analysis

Module 18: Mini-Grid System Design
• Load estimation
• Energy demand forecasting
• System sizing principles
• Solar array sizing
• Battery sizing
• Inverter sizing
• Cable sizing
• Voltage drop calculations
• Protection system design
Practical
• Design exercises
• Software-based system sizing
• Preparation of design reports

Module 19: Health, Safety and Environmental (HSE) Practices
• Electrical safety
• Working at heights
• Personal Protective Equipment (PPE)
• Fire prevention and response
• Lockout/Tagout procedures
• First aid procedures
• Environmental protection
Practical
• PPE usage
• Emergency drills
• Safety inspections

Module 20: Solar PV Installation Techniques
• Mounting structure installation
• Panel mounting procedures
• Cable management
• Earthing and grounding
• Lightning protection
Practical
• Installing mounting structures
• Mounting PV modules
• Cable routing and termination

Module 21: Battery Bank Installation
• Battery room requirements
• Battery configuration
• Series and parallel battery connections
• Battery protection systems
• Battery maintenance procedures
Practical
• Battery bank assembly
• Voltage testing
• Battery balancing

Module 22: Inverter and Control System Installation
• Inverter installation procedures
• Charge controller installation
• Control panels
• SCADA and remote monitoring basics
Practical
• Inverter wiring
• Controller setup
• Monitoring system configuration

Module 23: Mini-Grid Distribution Network Installation
Topics
• Pole erection
• Conductor stringing
• Service drops
• Meter installation
• Distribution safety
Practical
• Pole installation
• Cable stringing
• Meter installation

Module 24: Testing and Commissioning
• Pre-commissioning inspections
• Continuity testing
• Insulation resistance testing
• Grounding resistance testing
• Functional performance testing
• Commissioning procedures
Practical
• System testing
• Fault identification
• Commissioning checklist completion

Module 24: Operation and Maintenance (O&M)
• Preventive maintenance
• Corrective maintenance
• Troubleshooting procedures
• Performance monitoring
• Data collection and reporting
Practical
• Routine inspection
• Fault diagnosis
• Maintenance scheduling

Module 25: Mini-Grid Monitoring and Data Management
• Energy production monitoring
• Load monitoring
• Battery performance analysis
• Data logging systems
• Remote monitoring platforms
Practical
• Monitoring software usage
• Report generation

Module 26: Mini-Grid Business and Sustainability
Topics
• Tariff setting
• Revenue collection
• Customer management
• Productive use of energy
• Financial sustainability
• Regulatory requirements
Practical
• Tariff calculation exercise
• Customer service simulations

Module 27: Troubleshooting and Fault Finding
• Common PV system faults
• Battery failures
• Inverter faults
• Distribution network faults
• Metering faults
Practical
• Fault simulation exercises
• Corrective actions

Module 28: Project Management for Mini-Grid Installation
• Project planning
• Resource management
• Procurement
• Documentation
• Quality control
• Stakeholder engagement
Practical
• Installation project planning
• Work scheduling

Module 29: Capstone Project
Student Activities
• Conduct site assessment
• Design a mini-grid system
• Install solar modules
• Install batteries and inverter
• Wire the distribution network
• Test and commission the system
• Present project report
Deliverables
• Design drawings
• Bill of Quantities (BOQ)
• Installation report
• Commissioning report
• Maintenance plan

Certification assessment

BONUS (HIGH-VALUE ADDITIONS)
Real project case studies
Bill of Materials (BOM) preparation
Software tools (e.g., PVsyst,
Helioscope basics)
Proposal templates for client